Composition and method for low temperature chemical vapor deposition of silicon-containing films including silicon carbonitride and silicon oxycarbonitride films

ABSTRACT

Silicon precursors for forming silicon-containing films in the manufacture of semiconductor devices, such as films including silicon carbonitride, silicon oxycarbonitride, and silicon nitride (Si 3 N 4 ), and a method of depositing the silicon precursors on substrates using low temperature (e.g., &lt;550° C.) chemical vapor deposition processes, for fabrication of ULSI devices and device structures.

CROSS REFERENCE TO RELATED APPLICATIONS

This is a continuation-in-part of U.S. patent application Ser. No. 10/683,501 entitled “Monosilane or Disilane Derivatives and Method for Low Temperature Deposition of Silicon-Containing Films Using the Same,” filed on Oct. 10, 2003 in the names of Ziyun Wang, Chongying Xu and Thomas H. Baum.

FIELD OF THE INVENTION

The present invention relates generally to novel silicon-containing precursors and the formation of silicon-containing films using said precursors in the manufacture of semiconductor devices. More specifically, the present invention relates to silicon-containing precursors and methods for forming silicon-containing films, e.g., films including silicon carbonitride and silicon oxycarbonitride, on a substrate using low temperature (T<550° C.) chemical vapor deposition (CVD) processes.

DESCRIPTION OF THE RELATED ART

In semiconductor manufacturing, thin (e.g., <1,000 nanometers thickness) passive layers of chemically inert dielectric materials, such as silicon nitride (Si₃N₄), siliconoxynitride (SiO_(x)N_(y)) and/or silicon dioxide (SiO₂), are widely employed in microelectronic device structures, to function as structural elements of the multi-layered structure, such as sidewall spacer elements, diffusion masks, oxidation barriers, trench isolation coatings, inter-metallic dielectric materials, passivation layers and etch-stop layers.

Recently studies have shown that carbon incorporation (10-15%) in silicon nitride films is beneficial to film quality for transistor sidewall spacer applications. Etch stop and capping layers situated between low dielectric constant (low-k) layers also benefit from a mixture of carbon with silicon nitride or silicon oxide. In addition, pre-metal dielectric (PMD)-liners of silicon nitride require etch selectivity and diffusion barrier properties, which can be enhanced by carbon incorporation into the silicon nitride.

Silicon carbonitride (Si—C—N), which displays the properties of silicon nitride and silicon carbide, is both temperature and oxidation resistant. As such, Si—C—N material is being investigated for use as a hard mask, etch stop or a passivation layer for the Cu dual damascene process.

Si—C—N layers are generally grown using various plasma-enhanced chemical deposition techniques (PECVD).

Deposition of silicon-containing films by CVD techniques is a highly attractive methodology for forming such Si—C—N films. Towards that end, mixtures of monosilane, hydrocarbons, and ammonia or nitrogen have generally been used to synthesize Si—C—N films using CVD at elevated temperatures (T˜1300 K). For example, crystalline thin films of Si—C—N have been grown by microwave plasma enhanced CVD (PECVD) at temperatures above 800° C. using a mixture of H₂, CH₄, N₂ and SiH₄ gases. However, these mixtures tend to be explosive and flammable. (see, Chen, L. C., et al., Applied Physics Letters, 72, 2463-2465 (1998)). More recently, Si—C—N films have been deposited using PECVD at 350° C. to 400° C. using a mixture of trimethylsilane (3MS), helium and ammonia (see, Foresight, April 2003, publication of Applied Materials Taiwan). This disclosed deposition requires high plasma densities that can damage device structures if used in the “front end,” e.g., the PMD-liner.

To be compatible with the next generation IC device manufacturing, sidewall spacers need to be deposited by thermal CVD processes at low deposition temperatures, e.g., temperatures less than about 550° C., preferably about 530° C. Because of stringent conformality requirements and proximity to the transistor channel, the use of plasmas is not permitted. Presently used precursors, such as BTBAS, require very high precursor flow rates and have extremely low deposition rates at these temperatures, leading to very high processing costs. Thus, there is a significant need for suitable precursor compositions for such thermal deposition processes. Of particular interest are volatile organosilicon precursors containing appropriate ratios of silicon, nitrogen and carbon.

In addition, to be compatible with the next generation IC device manufacturing, PMD-liners need to be deposited at temperatures less than about 450° C., preferably about 400° C. For this application, low energy density plasmas would be acceptable. Further, etch stop and capping layers to be integrated with low k dielectrics and copper wiring need to be deposited at temperatures below about 400° C., preferably below about 350° C. These layers need to have high structural integrity, good barrier properties with respect to copper diffusion, and a dielectric constant significantly less than that of silicon nitride. For etch stop and capping layers application, PECVD is also acceptable. Again, volatile organosilicon precursors containing appropriate ratios of silicon, nitrogen and carbon are preferable.

Previously, we demonstrated that disilane precursors can offer high deposition rates at low temperatures. For example, silicon nitride films may be deposited at a rate of 26 Å/min by CVD at 450° C. using a mixture of hexaethylamidodisilane (HEADS) precursor and ammonia. Without being bound by theory, the high growth rate is attributed to the weak silicon-silicon bond in the disilane compound, which has a bond energy of 222 kJ/mol. In addition, it has been reported that higher temperatures induce lower deposition rates at the substrate because the reactant desorbs from the surface with the increase in temperature. Notably, disilane (Si₂H₆) and hexachlorodisilane (HCDS) (Si₂Cl₆), which have the weak Si—Si bond, also have been considered as promising precursors, however, they provide no source of carbon atoms. Further, chlorine may be incorporated into the fabricated chips, which could significantly reduce the chips long-term performance.

The art therefore has a continuing need for improved organosilicon precursors for forming silicon-containing films, such as low k silicon-containing thin films including silicon oxynitride, silicon nitride, silicon carbonitride and silicon oxycarbonitride.

SUMMARY OF THE INVENTION

The present invention relates generally to the formation of silicon-containing films in the manufacture of semiconductor devices, and more specifically to novel silicon precursors and methods for forming silicon-containing films, such as silicon-containing low k films and films comprising silicon carbonitride (Si—C—N), and silicon oxycarbonitride (Si—O—C—N), on a substrate using low temperature (T<550° C.) CVD processes.

The present invention in one aspect relates to a silicon compound selected from the group consisting of:

-   (A) Compounds of the Formula:     (R²R³N)_(3−x)R¹ _(x)Si—SiR¹ _(x)(NR²R³)_(3−x)     -   wherein:     -   R¹, R², and R³ may be the same as or different from one another         and each is independently selected from the group consisting of         H, C₁-C₅ alkyl, C₃-C₆ cycloalkyl, aryl, arylalkyl; and     -   x is 1 or 2); -   (B) Compounds of the Formula:

-   -   wherein R¹, R² and R³ may be the same as or different from the         other and each is independently selected from the group         consisting of H, C₁-C₅ alkyl, C₃-C₆ cycloalkyl, aryl and         arylalkyl; and     -   X, Y, and Z may be the same as or different from the other and         each is independently selected from the group consisting of H,         alkyl, alkylamino, dialkylamino and alkylhydrazido;     -   with the proviso that when R¹, R², X and Y are methyl groups and         R³ is hydrogen, Z cannot be hydrogen; and

-   (C) Compounds of the Formula:

-   -   wherein R¹, R² and R³ may be the same as or different from the         other and each is independently selected from the group         consisting of H, C₁-C₅ alkyl, C₃-C₆ cycloalkyl, aryl and         arylalkyl; and     -   X¹, X², Y¹, and Y²may be the same as or different from the other         and each is independently selected from the group consisting of         H, alkyl, alkylamino, dialkylamino and alkylhydrazido.

Another aspect of the present invention relates to a method of forming a silicon-containing film on a substrate, comprising contacting a substrate under chemical vapor deposition conditions, at a temperature below 600° C., with a vapor of a silicon compound selected from the group consisting of:

-   (A) Compounds of the Formula:     (R²R³N)_(3−x)R¹ _(x)Si—SiR¹ _(x)(NR²R³)_(3−x)     -   wherein:     -   R¹, R², and R³ may be the same as or different from one another         and each is independently selected from the group consisting of         H, C₁-C₅ alkyl, C₃-C₆ cycloalkyl, aryl, arylalkyl; and     -   x is 1 or 2; -   (B) Compounds of the Formula:

-   -   wherein R¹, R² and R³ may be the same as or different from the         other and each is independently selected from the group         consisting of H, C₁-C₅ alkyl, C₃-C₆ cycloalkyl, aryl and         arylalkyl; and     -   X, Y, and Z may be the same as or different from the other and         each is independently selected from the group consisting of H,         alkyl, alkylamino, dialkylamino and alkylhydrazido;     -   with the proviso that when R¹, R², X and Y are methyl groups and         R³ is hydrogen, Z cannot be hydrogen;

-   (C) Compounds of the Formula:

-   -   wherein R¹, R² and R³ may be the same as or different from the         other and each is independently selected from the group         consisting of H, C₁-C₅ alkyl, C₃-C₆ cycloalkyl, aryl and         arylalkyl; and     -   X¹, X², Y¹, and Y², may be the same as or different from the         other and each is independently selected from the group         consisting of H, alkyl, alkylamino, dialkylamino and         alkylhydrazido; and

-   (D) Compounds of the Formula:     (R¹R²N)₂Si:,  (i)     (R¹R²N)₂Si═Si(NR¹R²)₂,  (ii)     and     (R¹R²N)₂HSi—SiR³ _(n)H_(3−n),  (iii)     -   wherein R¹, R² and R³ may be the same as or different from the         other and each is independently selected from the group         consisting of H, C₁-C₄ alkyl, amino, silyl groups (—SiH₃) and         hydrocarbyl derivatives of silyl groups (e.g., —SiR₃); and         0≦n≦3.

Yet another aspect of the present invention relates to a method of making a silicon compound of the formula (R²R³N)_(3−x)R¹ _(x)Si—SiR¹ _(x)(NR²R³)_(3−x)

-   -   wherein:     -   R¹, R², and R³ may be the same as or different from one another         and each is independently selected from the group consisting of         H, C₁-C₅ alkyl, C₃-C₆ cycloalkyl, aryl, arylalkyl; and     -   x is 1 or 2;     -   said method comprising reacting a disilane compound of the         formula XR¹R²Si—SiXR¹R² with a secondary amine (R²R³NH) and a         tertiary amine (R¹R²R³N) compound, wherein X is selected from         the group consisting of bromine, fluorine and chlorine, and R¹,         R² and R³ are as set out above, according to the following         reaction:         XR¹R²Si—SiXR¹R²+R²R³NH+R¹R²R³N→(R²R³N)_(3−x)R¹ _(x)Si—SiR¹         _(x)(NR²R³)_(3−x)

Other aspects, features and embodiments of the invention will be more fully apparent from the ensuing disclosure and appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an STA plot for Me₂(NEt₂)Si—Si(NEt₂)Me₂ in Ar.

FIG. 2 is an STA plot for Me₄Si₂(NHNMe₂)₂ in Ar.

DETAILED DESCRIPTION OF THE INVENTION AND PREFERRED EMBODIMENTS THEREOF

The present invention relates to novel silicon precursors for the CVD formation of silicon carbonitride and/or silicon oxycarbonitride films on substrates at low temperatures, and to corresponding processes for forming such films with such precursors.

In one aspect, the invention provides a compound of the formula: (R²R³N)_(3−x)R¹ _(x)Si—SiR¹ _(x)(NR²R³)_(3−x)  (1)

-   wherein: -   R¹, R², and R³ may be the same as or different from one another and     each is independently selected from the group consisting of H, C₁-C₅     alkyl, C₃-C₆ cycloalkyl, aryl, arylalkyl; and -   x is 1 or 2.

The compounds of formula (1) are usefully employed for forming silicon-containing films by chemical vapor deposition, utilizing process conditions including a deposition temperature of less than 600° C., more preferably less than 550° C., and appertaining pressures, concentrations, flow rates and CVD techniques, as readily determinable within the skill of the art for a given application, based on the disclosure herein.

Silicon-containing films as defined herein means silicon nitride, silicon oxynitride, silicon carbonitride, silicon oxycarbonitride, low-k thin silicon-containing films, high-k gate silicate films and low temperature silicon epitaxial films.

Preferred compounds of formula (1) include Me₂(NEt₂)Si—Si(NEt₂)Me₂, Me₂(NEtMe)Si—Si(NEtMe)Me₂, and Me₂(NMe₂)Si—Si(NMe₂)Me₂.

Compounds of formula (1) are readily synthesized by reaction of disilane compounds of the formula R¹ ₂XSi—SiXR¹ ₂ with a secondary amine (R²R³NH) and a tertiary amine (R¹R²R³N) compound, wherein X is selected from the group consisting of bromine, fluorine and chlorine, and R¹, R² and R³ are as set out above. For example, Me₂(NEt₂)Si—Si(NEt₂)Me₂ can be prepared according to the following reaction: Me₄Si₂Cl₂+2 NEt₃+2 HNEt₂→Me₄Si₂(NEt₂)₂+2 NEt₃·HCl as hereinafter more fully described in the examples herein.

The invention in another aspect relates to a group of halogen-free silanes or disilane derivatives that are substituted with at least one alkylhydrazine functional group and can be used as CVD precursors for deposition of silicon-containing thin films.

The silane derivatives of the present invention can be represented by the general formula:

-   wherein R¹, R² and R³ may be the same as or different from the other     and each is independently selected from the group consisting of H,     C₁-C₅ alkyl, C₃-C₆ cycloalkyl, aryl and arylalkyl; and -   X, Y, and Z may be the same as or different from the other and each     is independently selected from the group consisting of H, alkyl,     alkylamino, dialkylamino and alkylhydrazido (e.g., R¹R²NNH—, wherein     R¹ and R² are the same as described hereinabove);     -   with the proviso that when R¹, R², X and Y are methyl groups and         R³ is hydrogen, Z cannot be hydrogen.

The silane derivatives of the present invention can also be represented by the general formula:

-   wherein R¹, R² and R³ may be the same as or different from the other     and each is independently selected from the group consisting of H,     C₁-C₅ alkyl, C₃-C₆ cycloalkyl, aryl and arylalkyl; and -   X¹, X², Y¹, and Y² may be the same as or different from the other     and each is independently selected from the group consisting of H,     alkyl, alkylamino, dialkylamino and alkylhydrazido.

Preferably, the disilane derivative compounds of the present invention are characterized by functional groups that are symmetrically distributed in relation to the Si—Si bond.

Compounds of formula (2) and (3) are readily synthesized by reaction of disilane compounds of the formula R¹ ₂XSi—SiXR¹ ₂ with an amine (R¹R²R³N) compound and a hydrazine compound (H₂NNR¹ ₂), wherein X is selected from the group consisting of bromine, fluorine and chlorine, and R¹, R² and R³ are as set out above. For example, Me₂(Me₂NNH)Si—Si(NHNMe₂)Me₂ can be prepared according to the following reaction: Me₄Si₂Cl₂+2 NEt₃+2 H₂NNMe₂→Me₄Si₂(NHNMe₂)₂+2 NEt₃·HCl as hereinafter more fully described in the examples herein.

The compounds of formulas (2) and (3) are usefully employed for forming silicon-containing films by chemical vapor deposition, utilizing process conditions including a deposition temperature of less than 600° C., more preferably less than 550° C., and appertaining pressures, concentrations, flow rates and CVD techniques, as readily determinable within the skill of the art for a given application, based on the disclosure herein.

Another class of silicon-containing precursors in accordance with the invention, which are amenable to CVD processes at low temperatures, such as in the range of from about 350° C. to about 550° C., for pre- and post-metal deposition of thin (e.g., 500 Angstroms to 1 micrometer thickness) dielectric films of silicon nitride or silicon oxynitride in semiconductor manufacturing, or otherwise for forming silicon nitride or silicon oxynitride ceramic thin films on different substrates, include the diaminosilylenes of formula (4) and their derivatives thereof, represented by formulae (5) and (6): (R¹R²N)₂Si:  (4) (R¹R²N)₂Si═Si(NR¹R²)₂  (5) (R¹R²N)₂HSi—SiR³ _(n)H_(3−n)  (6)

-   wherein R¹, R² and R³ may be the same as or different from the other     and each is independently selected from the group consisting of H,     C₁-C₄ alkyl, amino, silyl groups (—SiH₃) and hydrocarbyl derivatives     of silyl groups (e.g., —SiR₃); and -   0≦n≦3.

Diamino-silylenes as represented by formula (4) are diradical species, some of which are not stable and easily form the derivatives as represented in formulae (5) and (6), while others are remarkably stable and can be readily delivered in their diradical form.

An exemplary stable silylene compound includes the following diaminosilylene:

This diaminosilylene remains unchanged after boiling in toluene at 150° C. for four months. Thermal decomposition takes place at 220° C. The stability of this diaminosilylene is thought to result in part from aromatic stabilization (see, Denk, M., et al., J. Am. Chem. Soc., 116, 2691-2692(1994)).

Diaminosilylenes represented by formula (4) can be synthesized according to the following mechanism (see, West, R., Denk, M., Pure Appl. Chem., 68, 785-788 (1996)):

The compounds of formulae (5) and (6) can be made in accordance with the reaction scheme shown below:

In accordance with teaching herein, the type of dielectric film produced by the corresponding CVD process can be tailored by choice of the specific silicon-containing precursor of formulae (1)-(6). For example, ammonia, oxygen or nitric oxide may be used as alternative single reactants to form the respective silicon nitride, silicon oxynitride, silicon carbonitride and/or silicon oxycarbonitride single component films, or a mixture of two or more of such reactants can be employed in the CVD process with selected one(s) of the formulae (1)-(6) precursors to form corresponding multicomponent films, or graded composition films. Alternatively, mono-, di- and trialkyl amines, of the formula R¹R²R³N may be employed as reactants, wherein R¹, R² and R³ may be the same as or different from the other and each is independently selected from the group consisting of H and C₁-C₄ alkyl groups. In addition, inert carrier gases may be present in the precursor gas, including helium, argon and nitrogen.

In application, the silicon-containing precursor is reacted with a desired co-reactant in any suitable manner, e.g., in a single wafer CVD chamber, or in a furnace containing multiple wafers, utilizing process conditions including a deposition temperature of less than 600° C., more preferably less than <550° C., and appertaining pressures, concentrations, flow rates and CVD techniques, as readily determinable within the skill of the art for a given application, based on the disclosure herein. For example, when depositing sidewall spacers, PMD liners, or etch-stop and capping layers, temperatures of less than 550° C., less than 450° C., and less than 400° C., respectively, should be used. With respect to pressure, deposition pressures may range from about 1 Torr to about 80 Torr.

The features and advantages of the invention are more fully shown by the following illustrative and non-limiting examples.

EXAMPLE 1 Synthesis of Me₂(NEt₂)Si—Si(NEt₂)Me₂

In a 1 L flask, 300 mL of hexanes and 350 mL (1.6 M, 560 mmol) of n-butyllithium in hexanes were mixed. To this solution, 41 g of HNEt₂ (560 mmol) was added at 0° C. White precipitate material was observed immediately. Upon completion of the addition, the reaction flask was allowed to warm to room temperature and stirred for an additional hour. Then, 50 g of Me₄Si₂Cl₂ (270 mmol) in 100 mL of diethyl ether was slowly added to the flask at room temperature. The mixture was stirred overnight and filtered at room temperature. The crude product, 59 g (227 mmol. 85% yield) was obtained after removal of the volatiles from the filtrate. The pure product was obtained by vacuum distillation (b.p. −62° C. at 190 mTorr). ¹H NMR (C₆D₆): 0.26 (s, 12H, —CH₃Si); 1.00 (t, 12H, —CH₃CH₂N); 2.83(q, 8H, —CH₃CH₂N). ¹³C {¹H} NMR (C₆D₆): δ 0.33 (—CH₃Si); 16.2 (—NCH₂CH₃); 41.3 (—NCH₂CH₃). Mass spectrum: m/z 260 [M+]; 188 [M+-(—NEt₂)]; 130 [M+-(—SiMe₂(NEt₂)]. C₁₂H₃₂N₂Si₂: Found (theory), C, 54.98% (55.31%); H, 12.41% (12.38%); N, 10.66% (10.75%).

FIG. 1 shows that the STA data indicates that the T₅₀ value of Me₂(NEt₂)Si—Si(NEt₂)Me₂ is about 160° C., evidencing good volatility and transport properties for chemical vapor deposition.

EXAMPLE 2 Synthesis of Me₂(Me₂NNH)Si—Si(NHNMe₂)Me₂

A 3 L flask was filled with a solution comprising 2.5 L of hexanes, 50 grams (267 mmol) of Me₄Si₂Cl₂, and 57 grams (561 mmol) of anhydrous NEt₃. 34 grams of H₂NNMe₂ (561 mmol), dissolved in 100 mL of diethyl ether, was slowly added to the flask at room temperature. White precipitate was observed during the addition of H₂NNMe₂ to the solution. Following completion of the addition, the mixture was stirred overnight, filtered, and all volatile materials were removed from the filtrate under vacuum. The crude yield was 86% (54 g, 230 mmol). Vacuum distillation was used to purify the end product, which has a boiling point of approximately 45° C. at 35 mTorr. ¹H NMR (C₆D₆): δ 0.33 (s, 12H, —CH₃Si), 1.90 (br, 2H, —HN), 2.27 (s, 12H, —CH₃N). ¹³C{¹H} NMR (C₆D₆): δ −0.68 (—SiCH₃), 52.6 (—NCH₃). Mass spectrum: m/z 175 [M⁺-(—HNNMe₂)], 132 [M⁺-(—HNNMe₂)-(—NMe₂)], 116 [M⁺-(—SiMe₂(HNNMe₂)]. C₈H₂₆N₄Si₂: Found (calculated) C,: 40.81% (40.98%); H,: 10.99% (11.18%); and N,: 23.67% (23.89%).

FIG. 2 shows the STA plot for Me₄Si₂(NHNMe₂)₂, which is a liquid at room temperature and can be transported in its vapor form completely with very little (<1%) residual material at about 350° C. The thermal stability of Me₄Si₂(HNNMe₂)₂ in solution at 100° C. was monitored by proton NMR study for 7 days, and no significant decomposition was detected.

EXAMPLE 3 Silicon Carbonitride Deposition from Me₄Si₂(NHNMe₂)₂

A solution of the compound of Example 2, Me₄Si₂(NHNMe₂)₂, was prepared at a concentration of 0.40M in a hydrocarbon solvent. This solution was metered at 0.10 mL per minute (equivalent to about 2 sccm) with 10 sccm of He as a carrier gas and vaporized at 70° C. The vapor was mixed with 10 sccm of NH₃ in a showerhead device that was maintained at 100° C. and thereby dispersed over the surface of a Si(100) wafer heated to 550° C. The chamber pressure was maintained at 1 Torr during deposition. The film was deposited at a rate of 1.3 nm/minute.

Hydrocarbon solvents contemplated herein for use as precursor solvents include, but are not limited to, alkanes, alkenes, alkynes, cycloalkanes, aromatic compounds such as benzene and its derivatives thereof, alkanols and amines.

Chemical analysis of the film, using a combination of RBS (Rutherford Backscattering), HFS (Hydrogen Forward Scattering), and NRA (Nuclear Reaction Analysis) techniques, revealed that the film composition was 22.9% Si, 13.2% N, 33.1% C, 25.0% H and the index of refraction at 632 nm was 1.98.

While the invention has been described herein with reference to various specific embodiments, it will be appreciated that the invention is not thus limited, and extends to and encompasses various other modifications and embodiments, as will be appreciated by those ordinarily skilled in the art. Accordingly, the invention is intended to be broadly construed and interpreted, in accordance with the ensuing claims. 

1. A silicon compound of the formula

wherein R¹, R² and R³ may be the same as or different from the other and each is independently selected from the group consisting of H, C₁-C₅ alkyl, C₃-C₆ cycloalkyl, aryl and arylalkyl; and X¹, X², Y¹, and Y² may be the same as or different from the other and each is independently selected from the group consisting of H, alkyl, alkylamino, dialkylamino and alkylhydrazido; with the proviso that when each of R³ is H, and each of R¹, X¹, X², Y¹, and Y² is methyl, then both R² are not H or methyl.
 2. The silicon compound of claim 1 of the formula (Me₂NNMe)Me₂Si—SiMe₂(MeNNMe₂). 